Heat exchanger exterior surface cleaning system, method of retrofitting a heat exchanger with a cleaning system, and method of cleaning a heat exchanger

ABSTRACT

A cleaning system may be used with a heat exchanger having a core and a fan. The core may include a first core face and an oppositely disposed second core face. The cleaning system may include a plurality of wash nozzles arranged between the first core face and the fan of the heat exchanger. The cleaning system may be used while the heat exchanger is in operation, reducing the downtime of the heat exchanger. A method of retrofitting a heat exchanger with a cleaning system may include arranging a plurality of wash nozzles between the first core face and the fan of the heat exchanger. A method of cleaning a heat exchanger may include arranging a plurality of wash nozzles between the first core face and the fan, supplying a cleaning fluid to the plurality of nozzles, and initiating a cleaning cycle while the heat exchanger is in operation so that the fan assists in moving the cleaning fluid through the core and removing accumulated debris from the second core face.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Application 62/786,009, filed Dec. 28, 2019.

BACKGROUND Technical Field

Embodiments of this disclosure are directed to a system for cleaning a surface of a heat exchanger and associated method.

Discussion of Art

Current methods and systems for cleaning the exterior surfaces of heat exchangers require the entire system, including the engine and fan, to be turned off to allow for a technician or other employee to have safe access to the exchanger components. Upon shutdown, a fan guard may be removed and the technician uses standard cleaning equipment, such as pressure washers and/or standard water hoses to spray off the core and remove dirt/dust/particulates and any other debris from the surface of the heat exchanger to ensure adequate airflow therethrough. Another cleaning method currently in use is to apply water through the air outlet side of the heat exchanger. However, this method may require shutdown of the heat exchanger system. Both processes can be time intensive, require the use of high pressure in the pressure washer, i.e., from 1000-2000 psi, to achieve sufficient cleaning of the heat exchanger, and result in downtime of the heat exchanger system during the cleaning process. Furthermore, cleaning at these high-pressures can cause damage to the heat exchanger. It may be desirable to have a system and method that differ from those currently available.

BRIEF DESCRIPTION

In accordance with one embodiment, a cleaning system may be used with a heat exchanger. The heat exchanger may have a core and a fan. The core may include a first core face and an oppositely disposed second core face. The cleaning system may include a plurality of wash nozzles arranged between the first core face and the fan of the heat exchanger.

In accordance with one embodiment, a method of retrofitting a heat exchanger with a cleaning system may include arranging a plurality of wash nozzles between a first core face of a core of the heat exchanger and a fan of the heat exchanger. The core may include the first core face and an oppositely disposed second core face.

In accordance with one embodiment, a method of cleaning a heat exchanger while the heat exchanger is in operation may include arranging a plurality of wash nozzles between a first core face of a core of the heat exchanger and a fan of the heat exchanger. The method may further include supplying a cleaning fluid to the plurality of nozzles and initiating a cleaning cycle while the heat exchanger is in operation so that the fan assists in moving the cleaning fluid through the core and removing accumulated debris from the second core face

BRIEF DESCRIPTION OF THE DRAWINGS

The inventive subject matter may be understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:

FIG. 1 is a rear perspective of a heat exchanger wherein the fan guard has been removed showing the cleaning system in accordance with one embodiment;

FIG. 2 is a rear perspective view of the heat exchanger of FIG. 1 with the fan guard in place showing the instrumentation used to activate/control the cleaning system in accordance with one embodiment;

FIG. 3 shows a partial perspective view of the heat exchanger of FIG. 2 including the instrumentation used to activate/control the cleaning system in accordance with one embodiment;

FIG. 4 is a front perspective view of the heat exchanger of FIG. 1 showing the core side of the heat exchanger in accordance with one embodiment;

FIGS. 5A and 5B are front and side schematic views of the heat exchanger including the cleaning system in accordance with one embodiment;

FIG. 6 is a side perspective view of the heat exchanger of FIG. 1 wherein the cleaning system is running in accordance with one embodiment;

FIG. 7 is a close-up view of one of the spray nozzles in operation for cleaning the heat exchanger of FIG. 1 in accordance with one embodiment;

FIG. 8 is a partial perspective view of the wash nozzles mounted in the heat exchanger of FIG. 1 in accordance with one embodiment;

FIGS. 9A and 9B are partial views of the top right core section of the heat exchanger of FIG. 1 before and after cleaning with the cleaning system in accordance with one embodiment;

FIGS. 10A and 10B are partial views of the middle right core section of the heat exchanger of FIG. 1 before and after cleaning with the cleaning system in accordance with one embodiment;

FIGS. 11A and 11B are partial views of the middle left core section of the heat exchanger of FIG. 1 before and after cleaning with the cleaning system in accordance with one embodiment;

FIGS. 12A and 12B are partial views of the top middle core section of the heat exchanger of FIG. 1 before and after cleaning with the cleaning system in accordance with one embodiment;

FIGS. 13A and 13B are partial views of the bottom right core section of the heat exchanger of FIG. 1 before and after cleaning with the cleaning system in accordance with one embodiment;

FIGS. 14A and 14B are front and side views of a cleaning assembly for use with the heat exchanger of FIG. 1 in accordance with one embodiment;

FIGS. 15A and 15B are front and side views of a cleaning assembly for use with the heat exchanger of FIG. 1 in accordance with another embodiment of the present disclosure;

FIGS. 16A and 16B are front and side views of a cleaning assembly for use with the heat exchanger of FIG. 1 in accordance with one embodiment

FIG. 17 is a flowchart illustrating a method of retrofitting a heat exchanger with a cleaning system according to one embodiment; and

FIG. 18 is a flowchart illustrating a method of cleaning a heat exchanger while the heat exchanger is in operation according to one embodiment.

DETAILED DESCRIPTION

Embodiments of the subject matter described herein relate to a cleaning system for a heat exchanger that may be used to clean the heat exchanger while the heat exchanger is operating. The cleaning system may include a plurality of wash nozzles arranged between a fan of the heat exchanger and a first core face of a core of the heat exchanger. The cleaning system may use the fan to push cleaning fluid through the core of the heat exchanger at pressures that reduce the possibility of damaging the heat exchanger.

The cleaning system may be retrofit to heat exchangers to allow heat exchangers to be cleaned while operating. The plurality of wash nozzles may be arranged in a grid or generally circular or polygonal arrangement. At least some of the wash nozzles may be fluidly connected to each other to emit a cleaning fluid from a source of cleaning fluid.

Referring to FIGS. 1-8, a heat exchanger 10 in accordance with one embodiment may include a cleaning system 12. The heat exchanger 10 may include a core 14 having a first core face 16 and an oppositely disposed second core face 18, shown in FIG. 6. The heat exchanger 10 may further include a fan 20 that may be covered by a fan guard 22. The cleaning system 12, as shown in FIG. 1, where the fan guard 22 has been removed, and as shown in FIG. 8, may further include a plurality of wash nozzles 24 mounted between the first core face 16 and the fan 20 of the heat exchanger 10.

Referring to FIGS. 14A and 14B, in one embodiment the plurality of wash nozzles 24 may be arranged in a grid 26. Referring to FIGS. 15A and 15B, the plurality of wash nozzles 24 may be arranged in a generally circular arrangement 36. Although FIGS. 15A and 15B show the circular arrangement 36 as hexagonal, the plurality of nozzles may be arranged in another configuration, for example triangular, square, rectangular, pentagonal, octagonal, or other polygonal arrangement. At least some of the wash nozzles 24 maybe in fluid communication with each other, for example via a plurality of conduits 28. The conduits may be, for example, pipes or hoses. The plurality of wash nozzles 24 may be arranged in a variety of arrangements and/or patterns depending upon the size, shape and cleaning needs of the heat exchanger 10.

Referring to FIGS. 16A and 16B, in one embodiment the plurality of wash nozzles 24 are in fluid communication with each other via a conduit (e.g. a pipe) 28. The pipe 28 is connected at each end to a carriage 64 that is connected to a linear rail 66. The linear rails 66 are provided on a frame 72 that may be connected between the fan and the heat exchanger core. The carriage 64 may be a motorized carriage to move the pipe 28 and wash nozzles 24 back and forth along the linear rails 66 as shown by arrow 68. The pipe 28 and nozzles 24 are moved relative to the heat exchanger core 14 to provide cleaning fluid to the first core face 16. Each motorized carriage 64 may include, for example, a pinion gear that is rotated by a motor. The pinion gears may engage the linear rails 66 which may be in the form of racks. Other arrangements may be used. For example, each motorized carriage 64 may include a pulley that is rotated by a motor and engages the linear rail 66, which may be a rod that the pulley is engaged with.

The conduit 28 may be connected to a conduit (e.g. a hose) 62 that is connectable to a source of cleaning fluid. The conduit 62 may be supported by a carrier 70 that supports the conduit 62 as the end of the conduit 62 that is connected to the conduit 28 moves back and forth as shown by the arrow 68.

In the arrangement of the nozzles 24 the distance between the nozzles can be varied depending upon the particular size of the heat exchanger 10 and/or if certain locations on the second core face 18 of the heat exchanger 10 attract more debris 50 than other locations of the second core face 18 requiring the concentration of additional cleaning nozzles 24 at these particular locations.

Referring again to FIGS. 1-3, at least one conduit 40 or a plurality of conduits may be connected to a source of cleaning fluid (not shown) that may supply cleaning fluid 42 to the cleaning system 12. The at least one conduit may be, for example, a hose or a pipe. The cleaning fluid 42 can be water. Alternatively, a cleaning detergent or other type of cleaning fluid may be used, or the cleaning detergent or other type of cleaning fluid may be mixed with water as the cleaning fluid.

Referring to FIGS. 1 and 8, the fan 20 may act as a pressure source to push the cleaning fluid 42 emitted from the wash nozzles 24 through the first core face 16 and the core 14 to remove debris collected on the second core face 18. The wash nozzles 24 may emit the cleaning fluid 42 while heat exchanger 10 is operating. Prior art cleaning systems, for example power washing systems, may use high water pressures, i.e., from 1000-2000 psi, to achieve sufficient cleaning of the heat exchanger. Use of the cleaning system 12, in which the fan 20 is used as a pressure source, may result in the use of significantly reduced water pressures, for example less than 100 psi, such as between 50-70 psi. The cleaning system 12 may also include one or more temperature sensors 48, for example a thermocouple, as shown in FIG. 3, to monitor the temperature of the cleaning fluid.

FIGS. 9A and 9B are partial views of the top right core section of the heat exchanger 10 before and after cleaning. FIGS. 10A and 10B are partial views of the middle right core section of the heat exchanger 10 before and after cleaning. FIGS. 11A and 11B are partial views of the middle left core section of the heat exchanger before and after cleaning. FIGS. 12A and 12B are partial views of the top middle core section of the heat exchanger 10 before and after cleaning. FIGS. 13A and 13B are partial views of the bottom right core section of the heat exchanger 10 before and after cleaning.

Depending upon the amount of collected debris 50 on the second core face 18 of the heat exchanger 10, the use of the cleaning system 12 may result in an increase of airflow through the heat exchanger of approximately 8%, 11.5%, 14%, or even as much as 25% or more. The airflow can be measured with an anemometer 52, as shown in FIG. 2. The flow rate of the cleaning fluid 42 flowing through the hose(s) 40 and into the cleaning system can affect the amount and/or rate of removal of the debris 50 from the second core face 18. The speed of the fan 20 can also affect this amount of removal and/or rate of the removal of the debris 50. Other factors that can affect the amount removal of the debris 50 include the overall number of nozzles 24 used, the number of nozzles 24 per square foot, the distance between each of the nozzles 24, the angle of spray of the nozzles 24, the temperature of the cleaning fluid 42, the number of hoses 40, the diameter of the hose or hoses 40 connected to the cleaning system 12, the inner diameter of the connecting conduits 28, and/or the flow rate of the cleaning fluid through the connecting conduits and out of the nozzles 24.

The cleaning device 12 may be retrofitted to an existing heat exchanger 10 that includes a core 14 and a fan 20. Referring to FIG. 17, according to one embodiment, the method 500 includes arranging a plurality of wash nozzles 510, which are in fluid communication with each other via a plurality of conduits, between the first core face and the fan of the heat exchanger. The wash nozzles and conduits may be arranged according to various configurations, as discussed above, depending upon the shape and/or size of the heat exchanger. The method may further include connecting at least one conduit or multiple conduits to the plurality of wash nozzles 520. The at least one conduit or conduits may be a hose or a pipe(s). The at least one conduit or conduits may be associated with a source of cleaning fluid and the cleaning fluid my include water, with or without a detergent, or any other known type of cleaning fluid or material.

As discussed above, the fan 20 may act as a pressure source to push the cleaning fluid 42 emitted from the wash nozzles 24 through the first core face 16 and the core 14 to remove debris collected on the second core face 18. The wash nozzles 24 may emit the cleaning fluid 42 while the heat exchanger 10 is in operation. One or more thermocouples 48 may be attached to the heat exchanger to monitor the temperature of the cleaning fluid 42.

With reference to FIG. 18, a method of cleaning a heat exchanger 600 may be performed while the heat exchanger is in operation. The heat exchanger may include a core and a fan. The core may include a first core face and an oppositely disposed second core face. The method 600 may include arranging a plurality of wash nozzles between the first core face and the fan 610 and supplying a cleaning fluid to the nozzles 620. The cleaning fluid may be supplied to the plurality of nozzles directly or to a plurality of conduits that may connect at least some of the nozzles in fluid communication with each other. The method may further include initiating a cleaning cycle 630 while the heat exchanger is operating so that the fan assists in moving the cleaning fluid through the core and removing accumulated debris from the second core face.

The heat exchangers and methods according to the embodiments may be used in connection with a variety of different types, styles and models of heat exchanger units, circuits, or cores. For example, a heat exchanger including an air-to-air after-cooler assembly, wherein the plurality of tubes is laid out according to various arrangements, may be used according to the embodiments. As another example, the cleaning systems and methods according to the embodiments can be used with heat exchangers having any type of fin and tube arrangement. These arrangements may include, but are not limited to, staggered, parallel, canted, plate fin, Serpentine, CT, and the like.

A cleaning system may be used with a heat exchanger having a core and a fan. The core may include a first core face and an oppositely disposed second core face. The cleaning system may include a plurality of wash nozzles arranged between the first core face and the fan of the heat exchanger.

Optionally, the plurality of wash nozzles may be arranged in a grid and at least some of the nozzles are connected may be in fluid communication with each other by a plurality of conduits. Optionally, the plurality of wash nozzles are arranged in a generally circular shape and at least some of the plurality of nozzles may be connected in fluid communication with each other by a plurality of conduits.

Optionally, a source of cleaning fluid may be connected to the plurality of wash nozzles. Optionally, the source of cleaning fluid comprises at least one conduit. Optionally, the cleaning fluid comprises water and a detergent.

Optionally, the fan acts as a pressure source to push a cleaning fluid emitted from the plurality of wash nozzles through the first core face and the core to remove debris collected on the second core face. Optionally, the plurality of wash nozzles may emit the cleaning fluid while the heat exchanger is operating. Optionally, the cleaning system may further include a temperature sensor that monitors the temperature of the cleaning fluid.

A method may retrofit a heat exchanger with a cleaning system. The heat exchanger may include a core and a fan. The core may include a first core face and an oppositely disposed second core face. The cleaning system may include a plurality of wash nozzles. The method may include arranging the plurality of wash nozzles between the first core face and the fan of the heat exchanger.

Optionally, the plurality of wash nozzles may be arranged in a grid and at least some of the nozzles may be connected in fluid communication with each other by a plurality of conduits. Optionally, the plurality of wash nozzles may be arranged in a generally circular shape and at least some of the nozzles may be connected in fluid communication with each other by a plurality of conduits. Optionally, the method may include connecting at least one hose to the plurality of wash nozzles, wherein the at least one hose is associated with a source of cleaning fluid. Optionally, the cleaning fluid may include water and a detergent.

Optionally, the fan may act as a pressure source to push a cleaning fluid emitted from the plurality of wash nozzles through the first core face and the core to remove debris collected on the second core face. Optionally, the plurality of wash nozzles may emit a cleaning fluid while the heat exchanger is operating. Optionally, the method may include attaching a thermocouple to the heat exchanger for monitoring the temperature of the cleaning fluid.

A method may clean a heat exchanger while the heat exchanger is in operation. The heat exchanger may include a core and a fan and the core may include a first core face and an oppositely disposed second core face. The method may include arranging a plurality of wash nozzles between the first core face and the fan and supplying a cleaning fluid to the plurality of nozzles. The method may further include initiating a cleaning cycle while the heat exchanger is in operation so that the fan assists in moving the cleaning fluid through the core and removing accumulated debris from the second core face.

Optionally, the plurality of nozzles may be arranged in a grid and at least some of the plurality of nozzles may be connected in fluid communication with each other by a plurality of conduits. Optionally, the plurality of nozzles may be arranged in a generally circular pattern and at least some of the plurality of nozzles may be connected in fluid communication with each other by a plurality of conduits.

The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description may include instances where the event occurs and instances where it does not. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it may be related. Accordingly, a value modified by a term or terms, such as “about,” “substantially,” and “approximately,” may be not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges may be identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal”, and derivatives thereof shall relate to the embodiments as they are oriented in the drawing figures. However, the embodiments may assume various alternative variations, except where expressly specified to the contrary. Like reference numerals are being used throughout the drawings to depict like components throughout the figures. Specific devices illustrated in the attached drawings, and described in the specification, are simply exemplary embodiments. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not limiting.

This written description uses examples to disclose the embodiments, including the best mode, and to enable a person of ordinary skill in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The claims define the patentable scope of the disclosure, and include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

What is claimed is:
 1. A cleaning system for use with a heat exchanger having a core and a fan, the core includes a first core face and an oppositely disposed second core face, wherein the cleaning system comprises: a plurality of wash nozzles arranged between the first core face and the fan of the heat exchanger.
 2. The cleaning system of claim 1, wherein the plurality of wash nozzles are arranged in a grid and at least some of the nozzles are connected in fluid communication with each other by a plurality of conduits.
 3. The cleaning system of claim 1, wherein the plurality of wash nozzles are arranged in a generally circular shape and at least some of the plurality of nozzles are connected in fluid communication with each other by a plurality of conduits.
 4. The cleaning system of claim 1, wherein the plurality of wash nozzles are connected in fluid communication with each other by at least one conduit and the at least one conduit and the plurality of wash nozzles are movable relative to the core.
 5. The cleaning system of claim 1, further comprising a source of cleaning fluid connected to the plurality of wash nozzles, wherein the source of cleaning fluid comprises at least one conduit.
 6. The cleaning system of claim 5, wherein the cleaning fluid comprises water and a detergent.
 7. The cleaning system of claim 1, wherein the fan acts as a pressure source to push a cleaning fluid emitted from the plurality of wash nozzles through the first core face and the core to remove debris collected on the second core face.
 8. The cleaning system of claim 5, wherein the plurality of wash nozzles are configured to emit the cleaning fluid while the heat exchanger is operating.
 9. The cleaning system of claim 4, further comprising a temperature sensor that monitors a temperature of the cleaning fluid.
 10. A method of retrofitting a heat exchanger with a cleaning system, the heat exchanger including a core and a fan, the core including a first core face and an oppositely disposed second core face, the cleaning system comprising a plurality of wash nozzles, wherein the method comprises: arranging the plurality of wash nozzles between the first core face and the fan of the heat exchanger.
 11. The method of claim 10, wherein the plurality of wash nozzles are arranged in a grid and at least some of the nozzles are connected in fluid communication with each other by a plurality of conduits.
 12. The method of claim 10, wherein the plurality of wash nozzles are arranged in a generally circular shape and at least some of the nozzles are connected in fluid communication with each other by a plurality of conduits.
 13. The method of claim 10, further comprising connecting at least one conduit to the plurality of wash nozzles, wherein the at least one conduit is associated with a source of cleaning fluid.
 14. The method of claim 10, wherein the fan acts as an atomizer and sudser to generate a foam from the cleaning fluid prior to forcing the foam through at least one flow path of the heat exchanger.
 15. The method of claim 10, wherein the fan acts as a pressure source to push a cleaning fluid emitted from the plurality of wash nozzles through the first core face and the core and thereby to remove collected debris on the second core face.
 16. The method of claim 10, wherein the plurality of wash nozzles are configured to increase the velocity of one or more streams of a cleaning fluid while the heat exchanger is operating.
 17. The method of claim 10, further comprising monitoring the temperature of the cleaning fluid.
 18. A method of cleaning a heat exchanger while the heat exchanger is in operation, said heat exchanger including a core and a fan, the core includes a first core face and an oppositely disposed second core face, said method comprising: arranging a plurality of wash nozzles between the first core face and the fan; supplying a cleaning fluid to the plurality of nozzles; and initiating a cleaning cycle while the heat exchanger is in operation so that the fan assists in moving the cleaning fluid through the core and removing accumulated debris from the second core face.
 19. The method of claim 18, wherein the plurality of nozzles are arranged in a grid and wherein at least some of the plurality of nozzles are connected in fluid communication with each other by a plurality of conduits.
 20. The method of claim 18, wherein the plurality of nozzles are arranged in a generally circular pattern and at least some of the plurality of nozzles are connected in fluid communication with each other by a plurality of conduits. 